Self regulating mechanism for storage water heater

ABSTRACT

A self regulating mechanism for a storage water heater for preventing the operation of heating elements while the heating elements are not submerged comprises a liquid level switch and an electrical contactor which are each integrated with a storage water heater having at least a water tank, at least one heating element and thermostat pair, and an input voltage line. In operation, the electrical contactor is wired to selectively control the flow of electricity from the input voltage line to the thermostats and heating elements and the liquid level switch is operative to determine the water level and operate the switching of the electrical contactor based on whether the level of water in the water tank meets a predetermined threshold. As such, the electrical contactor will only permit electricity to flow to the heating element when the liquid level switch indicates that the water tank is substantially full.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates generally to heating devices and, moreparticularly, to a self regulating mechanism for a storage water heaterwhich automatically controls heating coil operation based on the waterlevel in the water storage tank.

Description of the Prior Art

The use and design of convention storage water heaters to provide theinstantaneous delivery of hot water is well established. Suchconventional storage water heaters generally operate by using a heatingmeans driven by a fuel, such as electricity or propane, to heat waterstored in a tank which then can be availed as desired throughconventional plumbing or other means. A problem which still exists,however, is that for storage water heaters which employ a electricallydriven heating means, such a heating means is subject to significantdamage if operated without sufficient water in the tank. Furthermore,when installing or testing such a water heater, it is often difficult toascertain the water level in the tank in order to know whether theheating means can be activated. Thus, there remains a need for aregulating mechanism for a storage water heater which automaticallyrestricts the operation of heating element when the heating elements arenot submerged in water. It would be helpful if such a self regulatingmechanism for a storage water heater was integrated into the top of thestorage water heater for ease of access. It would be additionallydesirable for such a self regulating mechanism for a storage waterheater to employ a liquid level switch which automatically interruptedthe flow of electricity to the heating elements when the water in thetank fell below a preset threshold.

The Applicant's invention described herein provides for a regulatingmechanism for a storage water heater adapted to control the flow ofelectricity to the heating elements of a storage water heater. Theprimary components in Applicant's self regulating mechanism are a liquidlevel switch and a contactor. When in operation, self regulatingmechanism for a storage water heater effectively prevents the heatingelements of a storage water heater from burning out. As a result, manyof the limitations imposed by prior art structures are removed.

SUMMARY OF THE INVENTION

A self regulating mechanism for a storage water heater for preventingthe operation of heating elements while the heating elements are notsubmerged. The self regulating mechanism comprises a liquid level switchand an electrical contactor which are each integrated with a storagewater heater having at least a water tank, at least one heating elementand thermostat pair, and an input voltage line. In operation, theelectrical contactor is wired to selectively control the flow ofelectricity from the input voltage line to the thermostats and heatingelements and the liquid level switch is operative to detect the level ofwater in the water tank and operate the switching of the electricalcontactor based on whether the level of water in the water tanksurpasses a threshold defined by the uppermost heating element in thewater tank. In this regard, the electrical contactor will only permitelectricity to flow to the heating element when the liquid level switchindicates that the water tank is substantially full.

It is an object of this invention to provide a need for a regulatingmechanism for a storage water heater which automatically restricts theoperation of heating element when the heating elements are not submergedin water.

It is another object of this invention to provide a self regulatingmechanism for a storage water heater integrated into the top of thestorage water heater for ease of access.

It is yet another object of this invention to provide a self regulatingmechanism for a storage water heater that employs a liquid level switchwhich automatically interrupted the flow of electricity to the heatingelements when the water in the tank fell below a preset threshold.

These and other objects will be apparent to one of skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a storage water heater with a selfregulating mechanism built in accordance with the present invention inan energizing position.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings and in particular FIG. 1, a selfregulating mechanism for a storage water heater 10 is shown as a liquidlevel switch 20 attached to the top of the inner water tank 11 of thestorage water heater 10 and an electrical contactor 21 positioned on topof the storage water heater 10 housing. As with conventional electricwater heaters, the storage water heater 10 includes the water tank 11, aplurality of heating elements 12, commonly defined as electrical coils,a thermostat 13 associated with each heating element, an input voltageline 14 which delivers electrical power from a source (generally a mainelectricity source), and hot and cold water lines 15.

In accordance with the self regulating mechanism of the instantdisclosure, the electrical contactor 21 is wired to selectively controlthe flow of electricity from the input voltage line 14 to thethermostats 13 and heating elements 12. In this regard, by the operationof the electrical contactor 21, a circuit can be selectively made toallow electricity from the input voltage line 14 to the thermostats 13and heating elements 12 and broken to interrupt to flow of electricityfrom the input voltage line 14 to the thermostats 13 and heatingelements 12.

In one embodiment, a pair of indicator lights are disposed on thestorage water heater 10. Such indicator lights, which may be positionedon the exterior of the housing of the electrical contactor 21, provide avisual indication of whether power is going to the contactor, and aseparate visual indication of whether the tank 11 if full and energized.In one embodiment, the indicator lights define LED lights.

In one embodiment, this switching operation of the electrical contactor21 is controlled by the operation of the liquid level switch 20.Specifically, the liquid level switch 20 is operative to detect thelevel of water in the water tank 11, specifically whether the water tankis full, and operate the switching of the electrical contactor 21 basedon whether the level of water in the water tank 11 equals thisthreshold. It is contemplated that with the tank 11 full, the uppermostheating element 12 in the water tank 11 is guaranteed to be submerged.In this regard, the liquid level switch 20, which is mounted adjacent tothe top of the water tank 11, is in its energizing position when itsfloat is actuated to indicate the presence of the water level. On theother hand, the liquid level switch 20 is in its interrupting positionwhen the float indicates a level of water beneath the top of the tank.In one embodiment, the liquid level switch 20 may define one of the L8Series Flotect® Liquid Level Switches from Dwyer®. In alternateembodiments, an equivalent liquid level switch may be employedalternatively.

While in the energizing position, the liquid level switch 20 energizesthe electrical contactor 21 to cause the electrical contactor 21 to makethe circuit between the input voltage line 14 and the thermostats 13 andheating elements 12 and while in the interrupting position, the liquidlevel switch 20 causes the electrical contactor 21 to break the circuitbetween the input voltage line 14 and the thermostats 13 and heatingelements 12.

In an alternate embodiment, an on/off float switch is employed with onetwo pole electrical contactor, with each electrical contactor associatedwith all of the thermostat and heating element pairs. In such anembodiment, the float switch has a lower threshold corresponding to thelowermost heating element and an upper threshold corresponding to theuppermost heating element and is operative to energize the electricalcontactor corresponding to the lowermost heating element while the lowerthreshold is exceeded and/or energize the electrical contactors notuntil the upper threshold is exceeded.

The instant invention has been shown and described herein in what isconsidered to be the most practical and preferred embodiment. It isrecognized, however, that departures may be made therefrom within thescope of the invention and that obvious modifications will occur to aperson skilled in the art.

What is claimed is:
 1. A self regulating mechanism for a storage waterheater, comprising: an electrical contactor integral with a storagewater heater and configured to selectively make and break a circuitwhich delivers electricity to at least one heating element integral witha water tank in the storage water heater, thereby controlling the flowof electricity to the at least one heating element; and at least oneswitch integral with the storage water heater and configured to detectwhether water in the water tank meets a predefined threshold andenergize the electrical contactor if the water in the water tank meetsthe predefined threshold so as to cause the electrical contactor to makethe circuit which delivers electricity to the at least one heatingelement.
 2. The self regulating mechanism of claim 1, wherein saidswitch is additionally configured to cause the electrical contactor tobreak the circuit which delivers electricity to the at least one heatingelement.
 3. The self regulating mechanism of claim 2, wherein theelectrical contactor is configured to selectively make and break acircuit which delivers electricity to the at least one heating elementthrough being wired between an input voltage line and the at least oneheating element.
 4. The self regulating mechanism of claim 2, wherein:the at least one heating element includes an uppermost heating elementand a lowermost heating element; and the predefined threshold defines awater level that is at least above the uppermost heating element.
 5. Theself regulating mechanism of claim 4, wherein the electrical contactoris configured to selectively make and break a circuit which deliverselectricity to the at least one heating element through being wiredbetween an input voltage line and the at least one heating element. 6.The self regulating mechanism of claim 1, wherein the switch defines aliquid level switch.
 7. A self regulating mechanism for a storage waterheater, comprising: an electrical contactor integral with a storagewater heater having a top surface, wherein the electrical contactor isconfigured to selectively make and break a circuit which deliverselectricity to at least one heating element integral with a water tankin the storage water heater, thereby controlling the flow of electricityto the at least one heating element; at least one liquid level switchintegral with the top surface of the storage water heater and configuredto detect whether water in the water tank meets a predefined thresholdand energize the electrical contactor if the water in the water tankmeets the predefined threshold so as to cause the electrical contactorto make the circuit which delivers electricity to the at least oneheating element; and said liquid level switch additionally configured tocause the electrical contactor to break the circuit which deliverselectricity to the at least one heating element.
 8. The self regulatingmechanism of claim 7, wherein the at least one heating element includesan uppermost heating element and a lowermost heating element and thepredefined threshold defines a water level that is at least above theuppermost heating element.
 9. The self regulating mechanism of claim 7,wherein the electrical contactor is configured to selectively make andbreak a circuit which delivers electricity to the at least one heatingelement through being wired between an input voltage line and the atleast one heating element.